Injection molding flow control apparatus and method

ABSTRACT

Injection molding apparatuses and methods wherein a valve pin is controllably driven upstream and downstream along an axis between a first closed position where the tip end of the valve pin obstructs the gate to prevent the injection fluid from flowing into the cavity, a full open position and one or more intermediate positions, wherein the valve pin is drivable to be disposed or held in a selected intermediate position for a selected period of time during the course of an injection cycle where the tip end of the valve pin restricts flow of injection fluid through the gate to the mold cavity.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of and claims the benefit of priority to U.S. application Ser. No. 16/054,386 filed Aug. 3, 2018, which is a continuation of and claims the benefit of priority to U.S. application Ser. No. 15/432,175 filed Feb. 14, 2017, which is a continuation of and claims the benefit of priority to U.S. application Ser. No. 14/930,692 filed Nov. 3, 2015, which is a continuation of and claims the benefit of priority to U.S. application Ser. No. 13/569,464 filed Aug. 8, 2012. The disclosures of these applications are incorporated by reference in their entirety as if fully set forth herein.

BACKGROUND

Injection molding systems have been developed having flow control mechanisms (e.g., a controller) that control the movement and/or rate of movement of a valve pin over the course of an injection cycle to cause the pin to move to one or select positions and/or to control the rate of movement of the pin over the course of the injection cycle. In one embodiment, the pin movement is controlled in order to raise or lower the rate of flow of fluid material to correspond to a predetermined profile of fluid flow rates for the injection cycle. A sensor is typically provided that senses a condition of the fluid material or of the apparatus (such as pin position) and sends a signal indicative of the sensed condition to a program contained in a controller that uses the signal as a variable input to control movement of the valve pin in accordance with the predetermined profile.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the invention, a flow control system is provided for implementing an injection molding process in which one or more nozzles, during an injection cycle, feed fluid material(s) into a cavity of a mold, each nozzle having an associated valve pin, driven by an associated actuator, for opening and closing a respective gate into the cavity, and a position sensor is associated with each valve pin for monitoring a plurality of actual pin positions with respect to the gate and generating a sensor output signal indicative of the plurality of actual pin positions as the valve pin moves between gate closed and gate open positions, the flow control system comprising:

a junction box coupled to a recipe storage on the mold and providing a wireless communication interface for transmitting and receiving wireless communications with each of:

-   -   a controller that controls movement of each valve pin over the         course of the injection cycle in accordance with a set of         process parameters, the controller being in wireless         communication with the junction box;     -   a mobile user interface, in wireless communication with the         junction box, configured to receive input from a human operator         in the form of process parameters and commands relating to the         injection molding process for wireless transmission to at least         one of the junction box and the controller;

the flow control system being configured to receive and process the sensor output signal from an associated position sensor to determine, from the plurality of actual pin positions, one or more actual process parameters; and

a user display being configured to receive and display the plurality of actual pin positions and/or the one or more actual process parameters by which a human operator can track the molding process in real time during the injection cycle.

In one embodiment, the user display is provided on the mobile user interface.

In one embodiment, the wireless communication interface comprises a radio frequency (RF) transceiver configured for bi-directional communication with the mobile user interface. The RF transceiver may consist of one or more of a Wi-Fi antenna, a Bluetooth antenna, and an NFC (Near Field Communication) antenna.

In one embodiment, the flow control system is configured to use the RF transceiver to transmit, to the mobile user interface, data indicative of the plurality of actual pin positions and/or the one or more actual process parameters.

In one embodiment, the flow control system is configured to use the RF transceiver to transmit, to the mobile user interface, data comprising one or more of: pin position status; pin opening and/or pin closing times; pin opening and/or pin closing velocities; and continuous actual pin position data for a graphical display of the plurality of actual pin positions versus time.

In one embodiment,

one or more of the junction box and the controller are configured to process the sensor output signal to generate a control signal to control the pin position; and

the mobile user interface is configured to receive user input for adjusting the control signal to control the pin position,

In one embodiment, the mobile user interface includes operator commands for one or more modes of operation including calibration, continuous monitoring of the actual pin position, and discrete determination of the actual pin position as opened or closed.

In one embodiment, calibration is triggered by input to the mobile user interface from the human operator.

In one embodiment, in response to the operator input, the mobile user interface is configured to generate a calibration command and transmit the calibration command to one or more of the junction box and the controller.

In one embodiment, one or more of the junction box and the controller are configured to calibrate the position sensor associated with each valve pin in response to the calibration command being received by one or more of the junction box and the controller.

In one embodiment, calibration data for each calibrated position sensor is stored locally in a memory of the junction box.

In one embodiment, the mobile user interface comprises a mobile telephone, smartphone, or tablet.

In one embodiment, the display comprises a display for viewing one or more of: a status indicator of the actual pin position; a graph of the actual pin position versus time; and the actual pin opening time and pin opening velocity.

In one embodiment, the position sensor comprises a Hall Effect sensor or a Hall Effect circuit including a Hall Effect sensor and one or more of a power regulator, signal amplifier, current converter, and signal driver.

In one embodiment,

the Hall Effect sensor generates a voltage output signal;

the voltage output signal is amplified and converted to a current output signal by the Hall Effect circuit; and

the current output signal is transmitted as the sensor output signal from an output port of the Hall Effect circuit to an input port of the junction box or the controller.

In accordance with one embodiment of the invention, a method is provided of monitoring valve pin positioning in an injection molding system having a cavity with one or more gates and one or more actuator-driven valve pins each associated with a respective gate for opening and closing the respective gate, the method comprising, for each of the respective actuator-driven valve pins:

controlling, via a flow control system that implements a set of process parameters for controlling a molding process in the cavity, an actuator that drives an associated valve pin with respect an associated gate of the cavity along a travel path including a plurality of actual pin positions between gate open and gate closed positions;

detecting, via a position sensor that monitors movement of an associated valve pin while the valve pin moves along the travel path between the gate closed position, closing the associated gate to the cavity, to the gate open position, allowing fluid material to flow through the gate and into the cavity, and transmitting as a position sensor output signal to the flow control system a detected actual movement of the valve pin along the travel path upon opening of the gate indicative of an actual pin opening velocity and an actual pin opening time;

receiving the position sensor output signal and generating display data indicative of actual process parameters including the actual pin opening time and the actual pin opening velocity; and

displaying, via a user display, the display data enabling a human operator to track the actual process parameters in real time during the injection cycle including the actual pin opening time and the actual pin opening velocity;

wherein the flow control system includes a junction box coupled to a recipe storage on the mold and providing a wireless communication interface for transmitting and receiving wireless communications with each of the controller and a mobile user interface, and the method further comprising:

receiving, by the mobile user interface, input from a human operator in the form of process parameters or commands relating to the injection molding process for wireless transmission to at least one of the junction box and the controller.

In one embodiment of the method, the user display is provided on the mobile user interface.

In one embodiment, the method comprises using a radio frequency (RF) transceiver as the wireless communication interface to perform bi-directional communication with the mobile user interface.

In one embodiment of the method, the RF transceiver comprises one or more of a Wi-Fi antenna, a Bluetooth antenna, and an NFC (Near Field Communication) antenna.

In one embodiment, the displaying step includes generating as the display data continuous actual pin position data for a graphical display of the plurality of actual pin positions versus time and transmitting the display data to the mobile user interface via the RF transceiver.

In one embodiment, the controlling step includes:

using the position sensor output signal as a variable input to control subsequent movement of the valve pin in accordance with the actual process parameters; and

receiving, at the mobile user interface, user input for adjusting the control signal to control the pin position.

In one embodiment, the method is adapted for use in calibration of the injection molding system, wherein calibration is triggered by an input to the mobile user interface from the human operator.

In one embodiment of the method, the mobile user interface is configured to generate a calibration command and transmit the calibration command to one or more of the junction box and the controller via the RF transceiver.

In one embodiment, one or more of the junction box and the controller calibrate the position sensors associated with each valve pin in response to the calibration command being received by the RF transceiver.

In one embodiment, the method further comprises storing calibration data for each calibrated position sensor locally in a memory of the junction box.

In one embodiment, the displaying step comprises displaying a status indicator of the actual pin position for one or more of the pins of the injection molding system.

In one embodiment, the displaying step comprises displaying data comprising one or more of: pin position status; pin opening and/or pin closing time; pin opening and/or pin closing velocities; and continuous actual pin position data for a graphical display of the plurality of actual pin positions versus time.

In one embodiment of the method, the position sensor comprises one or more Hall Effect sensors for an associated valve pin.

In accordance with one embodiment of the invention, a flow control application is provided for monitoring flow control during an injection molding process in which one or more nozzles, during an injection cycle, feed fluid material(s) into a cavity of a mold, each nozzle having an associated valve pin, driven by an associated actuator, for opening and closing a respective gate into the cavity, and a controller controls movement of the valve pins over the course of the injection cycle in accordance with a set of process parameters, the flow control application providing an interactive screen and a user display on a mobile user interface and a wireless communication channel with at least one of a junction box and a controller for monitoring flow control during the injection cycle, wherein the interactive screen enables an operator to input process parameters or commands, via the wireless communication channel, for one or more of the controller and the junction box for performing a method including steps of:

monitoring, via a position sensor associated with each valve pin, a plurality of actual pin positions with respect to the gate and generating a sensor output signal indicative of the plurality of actual pin positions as the valve pin moves between gate closed and gate open positions;

processing, via the controller, the sensor output signal from the associated position sensor to determine, from the plurality of actual pin positions, one or more actual process parameters; and

displaying, on the user display, the plurality of actual pin positions and/or the one or more actual process parameters by which a human operator can track the molding process in real time during the injection cycle.

In one embodiment of the flow control application, the wireless communication channel comprises a radio frequency (RF) transceiver on the junction box configured for bi-directional communication with the mobile user interface.

In one embodiment of the flow control application, the RF transceiver comprises one or more of a Wi-Fi antenna, a Bluetooth antenna, and an NFC (Near Field Communication) antenna.

In one embodiment of the flow control application, the junction box is further configured to use the RF transceiver to transmit, to the mobile user interface, data indicative of the plurality of actual pin positions and the one or more actual process parameters.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which:

FIG. 1 is a schematic of one embodiment of the invention utilizing microcontrollers (MCUs) for monitoring and/or controlling an injection molding process, the system including a recipe MCU located at the mold and a flow control MCU preferably remote from (optionally local to) the mold, and various human operator interfaces remote from the mold for monitoring and/or providing input to the MCUs with regard to the injection molding process;

FIG. 2 is a flow chart illustrating one method embodiment of the invention;

FIG. 3 is a flow chart illustrating another method embodiment of the invention;

FIG. 4 is a flow chart illustrating another method embodiment of the invention;

FIG. 5 is a flow chart illustrating another method embodiment of the invention;

FIG. 6 is a schematic of one embodiment of an injection molding apparatus utilizing the invention during an injection molding cycle, namely a recipe (of process parameters) stored on a recipe storage system mounted in a mold is transmitted to and executed by a controller, the molding apparatus including a pair of sequential gates with a first gate entering a center portion of a mold cavity having been opened and now closed such that a first shot of fluid material has entered the cavity and traveled past the positions of a pair of second sequential gates (one at each end of the mold cavity), each second gate being open with its valve pin having traveled along an upstream restricted flow path RP allowing a second sequential shot of fluid material to flow into and merge with the first shot of material within the cavity;

FIGS. 6A-6E are schematic cross-sectional close-up views of the center and one of the lateral gates of the FIG. 6 apparatus showing various stages of the progress of injection;

FIG. 7 is a schematic of one embodiment of a hydraulically actuated valve pin in which at least one port of an actuator is connected to a flow restrictor so as to restrict the flow of hydraulic drive fluid and slow the opening of the valve pin by a selected lessening of pin opening velocity by use of a controller interconnected to the flow restrictor, the controller enabling the user to select a percentage of predetermined full open position velocity that the hydraulic drive supply to the actuator normally operates at full open velocity drive fluid pressure;

FIGS. 7A, 7B are schematic cross-sectional views of the hydraulic valves and restrictors used in the system of FIG. 6;

FIGS. 8A, 8B show various embodiments of piston sensors that can be used in a variety of implementations of the invention, the sensors shown in these figures being mounted so as to measure the position of the piston component of the actuator which is indicative of the position of the valve pin relative to the gate;

FIGS. 8C, 8D show embodiments using limit switches that detect and signal specific positions of the actuator that can be used to determine velocity, position and switchover to higher openness of valve restrictor and/or upstream velocity of travel of the actuator and valve pin;

FIGS. 9A-9D are a series of graphs representing actual pressure (versus target pressure) measured in four injection nozzles coupled to a manifold, such as in the apparatus of FIG. 6; and

FIG. 10 shows an interactive screen display of a user interface, such as that shown in FIG. 1, which screen is used to display, create, edit and store target profiles.

DETAILED DESCRIPTION

Various embodiments of the present invention are now described with reference to the drawings. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of one or more implementations of the present invention. It will be evident, however, that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the present invention.

As used in this application with regard to various monitoring and control systems, the terms “component” and “system” are intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component may be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a server and the server can be a component. One or more components may reside within a process and/or thread of execution and a component may be localized on one computer and/or distributed between two or more computers.

The present invention may also be illustrated as a flow chart of a process of the invention. While, for the purposes of simplicity of explanation, the one or more methodologies shown in the form of a flow chart are described as a series of acts, it is to be understood and appreciated that the present invention is not limited by the order of acts, as some acts may, in accordance with the present invention, occur in a different order and/or concurrent with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all illustrated acts may be required to implement a methodology in accordance with the present invention.

In various embodiments of the invention disclosed herein, the term “data” is used. Data means any sequence of symbols (typically denoted “0” and “1”) that can be input into a computer, stored and processed there, or transmitted to another computer. As used herein, data includes metadata, a description of other data. Data written to storage may be data elements of the same size, or data elements of variable sizes. Some examples of data include information, program code, program state, program data, other data, and the like.

As used herein, computer storage media includes both volatile and non-volatile, removable and non-removable media for storage of information such as computer-readable instructions, data structures, program modules, or other data. Computer storage media includes RAM, ROM, EEPROM, FLASH memory or other memory technology, CD-ROM, digital versatile disc (DVDs) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store desired information and which can be accessed by the computer.

The methods described below may be implemented in a suitable computing and storage environment, e.g., in the context of computer-executable instructions that may run on one or more processors, microcontrollers or other computers. In a distributed computing environment (for example) certain tasks are performed by remote processing devices that are linked through a communications network and program modules may be located in both local and remote memory storage devices. The communications network may include a global area network, e.g., the Internet, a local area network, a wide area network or other computer network. It will be appreciated that the network connections described herein are exemplary and other means of establishing communications between the computers may be used.

A computer may include one or more processors and memory, e.g., a processing unit, a system memory, and system bus, wherein the system bus couples the system components including, but not limited to, the system memory and the processing unit. A computer may further include disk drives and interfaces to external components. A variety of computer-readable media can be accessed by the computer and includes both volatile and nonvolatile media, removable and non-removable media. A computer may include various user interface devices including a display screen, touch screen, keyboard or mouse. In some embodiments, a computer can be provided as a desktop computer, a laptop computer, a portable computing device, a mobile phone, a tablet, etc.

A microcontroller (MCU) is used in the present invention to control some or all of the functions of an electronic device or system. An MCU is a small self-contained computer chip, essentially comprising a small computer on a single integrated circuit and including a microprocessor, memory, and I/O on a single chip. The chip may be programmed for select functions, the program code being stored on Flash, EPROM or other non-violate memory. An MCU is used in each of a recipe storage system, a flow control system, and a user interface system in the embodiment described below. The MCU may be embedded in a printed circuit board (PCB), e.g., within the main PCB of the controller, a PCB within a storage device (in a junction box) and/or a PCB within an input device (such as a voice input interface). In contrast, PLC's (programmable logical controllers) are costly and not as effective (too slow and/or offer limited functionality).

Flow Control Apparatus and Method

FIG. 1 is a schematic diagram of a flow control apparatus and method according to one embodiment of the invention. In the disclosed embodiment, a recipe storage MCU and flow control MCU replace the prior known controller, and preferably communicate with a new operator interface. It is to be understood that the new flow control apparatus and method can be used with various injection molding machines and molding processes known to the skilled person.

In the advanced flow control system 10 of the present embodiment, a controller 8 includes a flow control microcontroller (MCU) 9, also referred to as the main MCU. The main MCU 9 is operative to communicate (over wired or wireless media 29) with one or more types of user interfaces 21 including for example a voice activated interface 23, a mobile (Wi-Fi) interface 25, and a wired interface 27. In some embodiments, one or more of the types of user interfaces 21 can be provided on a computing device that is separate from controller 8 and main MCU 9. For example, mobile (Wi-Fi) interface 25 could be provided as an application running on a mobile phone of a user (human operator) 31. Although reference is made to mobile interface 25 being a Wi-Fi interface, it is appreciated that various other wireless and radio frequency communication protocols can be utilized to implement mobile interface 25, including but not limited to, Wi-Fi, Bluetooth, NFC (Near Field Communication), etc. Such a mobile application can allow user 31 to use the same mobile phone to connect with, monitor, and/or interact with multiple mold and injection molding machines 41 (and their respective MCUs), which can be particularly advantageous in a factory setting where multiple mold and injection molding machines are utilized. More generally, user 31 can input to the interface 21 various process parameters, such as inputs to a recipe for controlling various types of actuators used in the molding process. The inputs will be transmitted from the user interface 21 to the main flow control MCU 9. The flow control MCU 9 in turn communicates (over wired or wireless media 51) with a remote recipe storage MCU 16 mounted on a mold 40 of an injection molding apparatus 41 (also referred as to an injection molding machine 41). Wireless media 51 can be provided by various radio frequency (RF) communication protocols as described above. The mold includes one or more pins (see FIG. 6) each driven by an actuator 45 for opening and closing one or more respective mold cavities (see FIG. 6). The actuator may be any type of known actuator, including electrical, hydraulic, or pneumatic actuators. The actuator drives a pin for opening and closing a gate (an opening into the mold cavity), and the movement of the pin may be monitored by one or more sensors or signals on/from the mold 40 or machine 41 for determining one or more process parameters such as pin position, pin velocity, or melt pressure in the cavity or in a fluid channel upstream of the cavity (e.g., manifold), or temperature in the cavity or in a fluid channel upstream of the cavity, or the mold cycle count. The recipe, for a respective mold, is stored in the recipe storage MCU 16 which is mounted on the mold 40, and the recipe is electronically transmitted from the recipe MCU 16 to the main MCU 9, remote from the mold, the latter of which implements computer instructions for controlling various parameters related to the molding process of the respective mold in accordance with the recipe.

In one example, the flow control (main) MCU 9 will automatically obtain or receive the recipe of process parameters (e.g., set-up information) from the remote recipe MCU 16 which is located on the mold 40 or machine 41. This allows for uninterrupted mold changes, namely the mold and its associated recipe will be read automatically by the flow control MCU 9, without requiring programming of the flow control MCU. The transmitted recipe data can be implemented by executing the flow control computer instructions stored on the flow control MCU 9. For example, the flow control MCU can be used to control the velocity of the pin(s), maintain the melt pressure at a desired melt pressure profile, and/or sequence the pin(s) in a mold using various other inputs.

Furthermore, the flow control (main) MCU 9 receives as input(s) from the mold 40 and/or machine 41 one or more electronic signals (digital or analog), over communication channels 51, indicative of the molding process, thus providing a feedback loop for one or more process parameters, e.g., for pressure control based on melt pressure and/or cavity pressure. This feedback can be provided or displayed to an operator 31, allowing the operator to input changes to the recipe, and the modified recipe can then be executed by the main MCU (as the new current recipe).

In one embodiment, the recipe storage MCU 16 is mounted on an electrical junction box 17 (a container for electrical connections) which allows for communications between the mold 40 and the flow control MCU 9 in order to retrieve and store recipes on the mold MCU 16. In some embodiments, the electrical junction box 17 associated with mold MCU 16 can further be configured with a communication interface to transmit and receive data in a wired or wireless fashion (51,29). For example, the electrical junction box 17 could be configured with one or more of a Bluetooth antenna, a Wi-Fi antenna, an NFC (Near Field Communication) antenna, etc., configured to function as a transmitter, receiver, and/or transceiver of wireless communication interface 17 a. These examples are not intended to be construed as limiting, as it is appreciated that various other Radio Frequency (RF) antennae and transmission protocols can be employed without departing from the scope of the present disclosure. As shown in FIG. 1, several wireless communication channels 29 a couple the wireless interface 17 a of junction box 17 to controller 8 (with main MCU 9), to WiFi Mobile User Interface 25 (with WiFi MCU 25 a and display 25 b), and to display 71; wireless interface 17 a can implement a greater of lesser number of wireless channels than shown in FIG. 1. In some embodiments, the communication interface 17 a can be provided as a separate component, or in a second junction box, and communicatively coupled with the electrical junction box 17 in order to provide wireless transmitting and receiving functionalities. The communication interface 17 a can be provided with a standalone power source, can draw power from a common feed on mold 40 or machine 41 (i.e. upon which the communication interface is mounted), can draw power from a common feed or source to electrical junction box 17, or some combination of the above. In addition to communicating the recipe data, the flow control MCU 9 can interact (e.g., via the junction box 17) with various optional sensors 50 and signals 53-55 on/from the mold and machine, such as position sensors, melt pressure sensors, cavity pressure sensors, temperature sensors, screw position and other injection molding machine sensor and signals to control the actuation of each pin in the mold, or the mold cycle count. FIG. 1 shows various signals 51, including recipe signal 52, position signal 53, melt pressure signal 54 and cavity pressure signal 55, being electronically transmitted from the mold machine to the remote main MCU 9, e.g., via wired or wireless communication channel(s), although for purposes of visual clarity these various signals 51 are not depicted as first passing through a junction box 17 and/or mold MCU 16, as has been described above.

As previously described, the user interface 21 enables a user 31 (human operator) to observe the tracking of the actual process parameters, versus the target (desired) process parameters, during the injection cycle in real time, or after the cycle is complete. In one example, the interface 21 includes an associated display 22 for tracking such parameters. One type of display is a simple indicator panel (similar to panel 61 shown in communication with the controller 8) that tells the operator whether the valve pin is open or closed. In this example, the control system can transmit discrete signals indicating whether the valve pin is closed or opened. In the previous example where the user interface 21 is a mobile (i.e. Wi-Fi and/or Bluetooth) interface 25, then the associated display 22 can be provided by the touch screen display of the user's smartphone, illustrated in FIG. 1 as display 25 b, where the user's smartphone runs a mobile application to provide the aforementioned information and data to the user and to further receive inputs and commands from the user.

In another example, a display (such as display 71) is provided that enables continuous position monitoring of the pin, by the user. In this example, the control system 8 transmits a signal to drive a display showing (e.g., in a graph of position versus time) the position of the valve pin throughout the injection cycle. In some embodiments, display 71 can also be provided by the touch screen display 25 b of the user's smartphone, either in combination with the mobile interface 25 functionality discussed above or as a standalone functionality. The graphical display 71 of pin position versus time can be transmitted directly to the smartphone or mobile computing device of human user 21 from a Wi-Fi, Bluetooth, or other RF antenna that is provided within or otherwise communicatively coupled with the junction box on mold and injection machine 41. In some embodiments, display 71 can alternatively or additionally be provided as a component of indicator panel 61, such that the panel 61 provides both a status indication of pin position (e.g. a green light indicates Pin Open; a yellow light indicates Pin in Transition; a red light indicates Pin Closed) and a visual or graphical indication of pin parameters including pin velocity and pin position vs. time.

The display(s) can be either local or remote with respect to flow control MCU 9, the user interface(s) 21, and/or the mold 40 and machine 41. In one example, the pin open/closed indicator panel 61 is mounted on an exterior portion or exterior surface of the injection molding machine 41, such that the indicator panel is visible to an individual observing the injection molding machine 41. In another example, the graphical display 71 (of pin position versus time) is provided on the user interface 21, such as on a display screen of a mobile telephone, smartphone, tablet or other computer device. As discussed above, the data comprising graphical display 71 can be wirelessly transmitted to the mobile telephone of user 31 via a Wi-Fi, Bluetooth, NFC, or other RF interface that is associated with or communicatively coupled to the electrical junction box located on injection molding machine 41 (i.e. the electrical junction box which houses the recipe/mold MCU 16).

In one embodiment, the user interface 21 is a voice activated interface 23 and includes a voice interpreter MCU 23 a. Such an interface may utilize any of various readily available components, such as a voice recognition chip. As the operator will typically have fairly specific and a limited range of inputs (commands), any of various commercially available voice recognition software can be used. For example, RSC-364 is a single chip that combines the flexibility of a microcontroller with advanced speech technology, including high-quality speech recognition, speech and music synthesis, speaker verification, and voice record and playback. A product can use one or all of the RSC-364 features in a single application. (See, e.g., http://www.sensoryinc.com)

In another embodiment, the operator interface 21 is a mobile interface 25, such as a Wi-Fi interface, that can be accessed via a local wireless hot spot or other wireless communication interface such as the Wi-Fi, Bluetooth, NFC, and other RF antennae and communication interfaces discussed above. In some embodiments, the local wireless hot spot can be provided by one or more of the RF communication interfaces discussed above. The wireless device can be any of various mobile laptops, tablets, smartphones, or other forms of computers that can run applications and/or a browser. In one example, a Wi-Fi MCU 25 a receives input via the mobile device from the human operator 31 and communicates parameters/commands to the flow control MCU 9. This would enable the operator to travel around an injection molding facility or plant, while using the same display and mobile computing device to both monitor data (e.g. pin position status, pin opening and closing times/speeds, pin position vs. time) and input commands to and from multiple injection molding machines. Further, assuming the mobile device includes a display screen providing process feedback on the existing profile data, the operator can then generate and transmit changes to the recipe from the user interface to the mold MCU 16 (either directly or via the main MCU 9). The modified recipe can then be stored at the mold MCU 16 as the (new) current recipe.

In some embodiments, the user 31 can additionally utilize his or her mobile computing device (e.g. smartphone or tablet) to perform a calibration process on one or more injection molding machines. In particular, the user 31 can use the aforementioned mobile application running on his mobile computing device to communicate with a given injection molding machine 41 via the Wi-Fi, Bluetooth, or other RF communication interface that is housed in or coupled to the junction box on the given injection molding machine. The calibration process can be performed with respect to the valve pins and position sensors of the injection molding machine 41 (more detailed discussion of the pins and associated position sensors is subsequently provided with respect to the valve pins 1040-1042 and position sensors 1950-195 of FIG. 6). Calibration of pin position sensors (such as Hall Effect sensors) can be necessary because, even though each pin and associated actuator has a fixed stroke length, the output (i.e. sensed) voltage from the pin position sensor can vary slightly. For example, a first sensor might have a voltage output range of 1-4 V, while an otherwise identical second sensor might have a voltage output range of 1.5-3 V. Accordingly, a calibration process can be employed to mitigate the effects of these deviations in sensor voltage output range. For example, the calibration process for a given sensor can include one or more of correlating a first output voltage to a fully open pin position, correlating a second output voltage to a fully closed pin position, and calculating a voltage change per mm of stroke length of the pin (i.e. a V/mm parameter).

In one example, the calibration process begins with the user 31 first commanding all pins to the fully closed position. This command can be input directly into the injection molding machine 41, or can be input into the user's mobile computing device and transmitted to the injection molding machine 41 over the Bluetooth or other RF communication interface at the junction box of the injection molding machine. Once all of the pins are moved to the fully closed position, the user then transmits a calibration command which begins the actual calibration of the pin position sensors on the injection molding machine 41. In some embodiments, if a user attempts to transmit a calibration command before the pins are moved to the fully closed position, the user can be prompted or reminded to first move the pins to the fully closed position and then re-attempt the calibration command. Alternatively or additionally, the application running on the user's mobile computing device can automatically transmit a command to the Bluetooth or RF transceiver in the junction box of injection molding machine 41 to thereby cause the pins to be moved to the fully closed position before the calibration command is subsequently transmitted or initiated.

With the calibration process thus initiated, the pins are then moved from the fully closed position to the fully open position. Based on an analysis of the recorded sensor output voltages over all of the steps of the calibration process, the fully closed and fully open sensor output voltages can be calculated, along with the V/mm of stroke length, for each pin. In some embodiments, the user 31 can command the pins to move to the fully open position, e.g. by inputting the command directly into injection molding machine 41, or by inputting the command into the mobile application running on the user's mobile computing device such that the command is transmitted from the mobile computing device to the injection molding machine 41 by way of the Bluetooth antenna housed in the electrical junction box of the injection molding machine. In some embodiments, the calibration steps described above can be automated and triggered with a single user input (e.g. selection of a button or other User Interface element presented by the mobile application running on the user's smartphone or tablet). After calibration is completed, the generated calibration data can be saved to memory in the junction box of the injection molding machine 41 (i.e. saved to memory in the recipe MCU 16 that is housed within the junction box on the injection molding machine 41). In this manner, calibration parameters are stored locally on the particular injection molding machine to which they pertain, and the user 31 is able to connect to, monitor and operate multiple different injection molding machines, each with different calibration parameters, while using the same smartphone or tablet each time.

In a further alternative, the user interface 21 is a hardwired interface 27 (including e.g., display 22 and pendent MCU 27 a as shown in FIG. 1), such as a desktop computer or computer device with an input keyboard or graphical user interface. The one or more interfaces 23, 25, 27 can be connected to the main MCU 9 of controller 8 via wired or wireless communication channels 29.

Flow Control Method

FIG. 2 illustrates one method embodiment 200 of the invention. In step 210, the current recipe stored on a recipe storage MCU located on the mold, is transmitted to the remote main MCU. In the next step 212, the main MCU executes computer instructions to control the injection molding process in accordance with the current recipe.

Another method embodiment 300 of the invention is illustrated in FIG. 3. In a first step 310, the current recipe is transmitted from the recipe storage MCU located on the mold to the remote main MCU and stored as the (new) current recipe. In a next step 312, the current recipe is displayed. In step 314, a human operator (viewing the display) determines whether changes are required to the current recipe. If changes are required, then in step 316 the operator inputs changes to the current recipe via a remote human operator interface, creating a modified recipe. Next, at step 318, the modified recipe is transmitted to the main MCU and/or recipe storage MCU and stored as the (new) current recipe. Then the method proceeds to step 320, where the main MCU executes computer instructions to control the injection molding process in accordance with the current (modified) recipe. Alternatively, if no changes are required to the current recipe (at step 314), then the method proceeds immediately to step 320 to execute the computer instructions in accordance with the current (unmodified) recipe.

FIG. 4 illustrates another method embodiment 400 of the invention. In a first step 410, the current recipe is transmitted from the recipe storage MCU located on the mold to the remote main MCU. In the next step 412, the main MCU executes computer instructions to control the injection molding process in accordance with the recipe. In the next step 414, process feedback is displayed, for example process parameters and/or molded part parameters from which the human operator can determine whether to make changes to the recipe. In the next step 416, the human operator determines whether changes to the current recipe are required. If so, in the next step 418 the operator inputs changes to the current recipe via a remote operator interface creating a modified recipe. In the next step 420, the modified recipe is transmitted to the main MCU and/or the recipe storage MCU. In the next step 422, the main MCU executes computer instructions to control the injection molding process in accordance with the new current (modified) recipe. Alternatively, if no changes are required (at step 414), then the method proceeds directly to step 422 to execute the computer instructions in accordance with the current (unmodified) recipe. In an optional further feedback loop, during or after step 422 the process returns to step 414 to display process feedback, wherein the operator can then determine at step 416 whether to further modify the current (or previously modified) recipe.

FIG. 5 illustrates a further method embodiment 500 of the invention. In a first step 510, a mold is added or changed having a recipe storage MCU located on the mold storing the current recipe. In a next step 512, the current recipe is transmitted from the recipe MCU located on the mold to the remote main MCU. In a next step 514, the main MCU executes computer instructions to control the injection molding process in accordance with the current recipe. Thus, the method illustrated in FIG. 5 would allow a mold operator, such as a night-shift operator, to change the mold without having to input which recipe to run. The control system (e.g., of FIG. 1) will automatically identify the mold and run the current recipe stored on the mold without any human operator input required.

Injection Molding Apparatus and Method

FIG. 6 shows an injection molding system 1000, including a controller 1016 (with a flow control MCU 9 as per FIG. 1) and a recipe storage system 1010 (with a recipe storage MCU 16 as per FIG. 1), the latter of which is mounted on a mold 1002 according to one embodiment of the invention. In this example, three gates feed a mold cavity as specified by a recipe of process parameters stored on the mold storage device 1010 and transmitted via communication channel 1009 to the main MCU in controller 1016 for execution.

A central nozzle 1022 is shown in FIG. 6 feeding molten material from an injection molding machine 1001 through a main inlet 1018 to a distribution channel 1019 of a manifold 1039. The distribution channel commonly feeds three separate nozzles 1020, 1022, 1024 which all commonly feed into a common cavity 1030 of a mold 1002 to make one molded part. A central nozzle 1022 is controlled by actuator 1940 and arranged so as to feed into cavity 1030 at an entrance point or gate that is disposed at about the center 1032 of the cavity. As shown, a pair of lateral nozzles 1020, 1024 feed into the mold cavity 1030 at gate locations that are distal 1034, 1036 to the center gate feed position 1032.

As shown in FIGS. 6 and 6A-6E, the injection cycle is a cascade process where injection is effected in a sequence from the center nozzle 1022 first and at a later predetermined time from the lateral nozzles 1020, 1024. As shown in FIG. 6A the injection cycle is started by first opening the pin 1040 of the center nozzle 1022 and allowing the fluid material M (typically polymer or plastic material) to flow up to a position in the cavity just before 1100 b, the distally disposed entrance into the cavity of the lateral nozzle 1024. Once the fluid material has further travelled just past the entrance to nozzle 1024, at position 1100 p, the center gate 1032 of the center nozzle 1022 is typically closed by pin 1040 as shown in FIG. 6B. The lateral gates 1034, 1036 are then opened by upstream withdrawal of lateral nozzle pins 1041, 1042 as shown in FIGS. 6B-6E. The rate of upstream withdrawal or travel velocity of lateral pins 1041, 1042 is controlled as described below.

In alternative embodiments, the center gate 1032 and associated actuator 1940 and valve pin 1040 can remain open at, during and subsequent to the times that the lateral gates 1034, 1036 are opened such that fluid material flows into cavity 1030 through both the center gate 1032 and one or both of the lateral gates 1034, 1036 simultaneously.

When the lateral gates 1034, 1036 are opened and fluid material NM is allowed to first enter the mold cavity into the stream M that has been injected from center nozzle 1022 past gates 1034, 1036, the two streams NM and M mix with each other. If the velocity of the fluid material NM is too high, such as often occurs when the flow velocity of injection fluid material through gates 1034, 1036 is at maximum, a visible line or defect in the mixing of the two streams M and NM will appear in the final cooled molded product at the areas where gates 1034,1036 inject into the mold cavity. By injecting NM at a reduced flow rate for a relatively short period of time at the beginning when the gates 1034, 1036 are first opened and following the time when NM first enters the flow stream M, the appearance of a visible line or defect in the final molded product can be reduced or eliminated.

The rate or velocity of upstream withdrawal of lateral pins 1041, 1042 starting from the closed position is controlled via controller 1016 (FIGS. 6 and 7) which controls the rate and direction of flow of hydraulic fluid from a drive system 1700 to actuators 1940, 1941, 1942. A “controller,” as used generally herein, refers to electrical and electronic control apparatuses that comprise a single box or multiple boxes (typically interconnected and communicating with each other) that contain(s) all of the separate electronic processing, memory and electrical signal generating components that are necessary or desirable for carrying out and constructing the methods, functions and apparatuses described herein. Such electronic and electrical components may include programs, microprocessors, computers, PID controllers, voltage regulators, current regulators, circuit boards, motors, batteries and instructions for controlling any variable element discussed herein such as length of time, degree of electrical signal output and the like. For example a component of a controller, as that term is used herein, includes programs, controllers and the like that perform functions such as monitoring, alerting and initiating an injection molding cycle including a control device that is used as a standalone device for performing conventional functions such as signaling and instructing an individual injection valve or a series of interdependent valves to start an injection, namely move an actuator and associated valve pin from a gate closed to a gate open position. In addition, although fluid driven actuators are employed in the disclosed embodiments, actuators powered by an electric or electronic motor or drive source can alternatively be used as the actuator component. Another embodiment would have the controller dynamically control the movement of an actuator and associated valve pin in order to meet target pressure profiles based upon (closed loop) feedback received by the controller from the pressure sensor. Yet another embodiment would have the controller trigger the opening and/or closing of an actuator and associated valve pin based upon a sensed pressure or temperature condition within the cavity.

As shown in FIGS. 7A-7B, a supply of hydraulic fluid 1014 is fed first through a directional control valve 1750 mechanism that switches the hydraulic fluid flow to the actuator cylinders in either of two directions: fluid out to withdraw the pin upstream, FIG. 7A, and fluid in to drive the pin downstream, FIG. 7B. At the beginning of an injection cycle the gate of a lateral valve 1034, 1036 is closed and the hydraulic system is in the directional configuration of FIG. 7B. When a cycle is started, the directional configuration of the directional valve 1750 of the hydraulic system 1700 is switched by controller 1016 to the configuration of FIG. 7A. The hydraulic system includes a flow restriction valve 1600 that can vary the rate of flow of hydraulic fluid to the actuator 1941 under the control of the controller 1016 to vary the rate of travel, upstream or downstream of the piston of the actuator 1941 which in turn controls the direction and rate of travel of pin 1041. Although not shown in FIGS. 7A, 7B, the hydraulic system 1700 controls the direction and rate of travel of the pistons of actuators 1950 and 1952 in a manner similar to the manner of control of actuator 1951 via the connections shown in FIG. 6.

The user programs controller 1016 via data inputs on a user interface to instruct the hydraulic system 1700 to drive pins 1041, 1042 at an upstream velocity of travel that is reduced relative to a maximum velocity that the hydraulic system can drive the pins 1041, 1042 to travel. As described below, such reduced pin withdrawal rate or velocity is executed until a position sensor such as 1951, 1952 detects that an actuator 1941, 1942 or an associated valve pin (or another component), has reached a certain position such as the end point of a restricted flow path RP. A typical amount of time over which the pins are withdrawn at a reduced velocity is between about 0.01 and 0.10 second, the entire injection cycle time typically being between about 0.3 seconds and about 3 seconds, more typically between about 0.5 seconds and about 1.5 seconds.

FIG. 6 shows position sensors 1950, 1951, 1952 for sensing the position of their respective actuator cylinders (1940, 1941, 1942) and their associated valve pins (1040, 1041, 1042) and feeding such position information to controller 1016 for monitoring purposes. As shown, fluid material 1018 is injected from an injection machine into a manifold runner 1019 and further downstream into the bores 1044, 1046 of the lateral nozzles 1024, 1022 and ultimately downstream through the gates 1032, 1034, 1036. When the pins 1041, 1042 are withdrawn upstream to a position where the tip end of the pins 1041, 1042 are in a fully upstream open FO position such as shown in FIG. 6D, the rate of flow of fluid material through the gates 1034, 1036 is at a maximum. However when the pins 1041, 1042 are initially withdrawn beginning from the closed gate position, FIG. 6A, to intermediate upstream positions, FIGS. 6B, 6C, a gap 1154, 1156 that restricts the velocity of fluid material flow is formed between the outer surfaces 1155 of the tip end of the pins 1044, 1046 and the inner surfaces 1254, of the gate areas of the nozzles 1024, 1020. The restricted flow gap 1154, 1156 remains small enough to restrict and reduce the rate of flow of fluid material M through gates 1034, 1036 to a rate that is less than maximum flow velocity over a travel distance RP of the tip end of the pins 1041, 1042 going from closed to upstream as shown in FIGS. 6, 6B, 6C, 6E.

The trace or visible lines that appear in the body of a part that is ultimately formed within the cavity of the mold on cooling above can be reduced or eliminated by reducing or controlling the velocity of the pin 1041, 1042 opening or upstream withdrawal from the gate closed position to a selected intermediate upstream gate open position that is preferably 75% or more of the length of RP. RP can be about 1-8 mm in length and more typically about 2-6 mm and even more typically 2-4 mm in length. As shown in FIG. 7 in such an embodiment, a control system or controller 1016 is programmed to control the sequence and/or the rates of valve pin 1040, 1041, 1042 opening and/or closing.

The velocity of withdrawal of the valve pins 1041, 1042 is determined by regulation of the flow of hydraulic drive fluid that is pumped from a supply 1014 to the actuators 1941, 1942 through a flow restrictor valve 1600, FIGS. 6-7. When the flow restrictor valve 1600 is completely open, namely 100% open, allowing maximum flow of the pressurized hydraulic fluid to the actuator cylinders, the valve pins 1041, 1042 are driven at a maximum upstream travel velocity. The degree of openness of the flow restrictor valve is adjusted in response to sensing of position of a suitable component such as an actuator 1941, 1942 or associated valve pin to less than 100% open. Adjustment of the flow restrictor valve 1600 to less than 100% open thus reduces the rate and volume flow of pressurized hydraulic fluid to the actuator cylinders thus in turn reducing the velocity of upstream travel of the pins 1041, 1042 for the selected period of time. At the end of the travel or length of path RP, a position sensor signals the controller 1016, the controller 1016 determines that the end has been reached and the valve 1600 is opened to a higher velocity, typically to its 100% open position to allow the actuator pistons and the valve pins 1041, 1042 to be driven at maximum upstream velocity in order to reduce the cycle time of the injection cycle.

The valve 1600 typically comprises a restrictor valve that is controllably positionable anywhere between completely closed (0% open) and completely open (100% open). Adjustment of the position of the restrictor valve 1600 is typically accomplished via a source of electrical power that controllably drives an electromechanical mechanism that causes the valve to rotate such as a rotating spool that reacts to a magnetic or electromagnetic field created by the electrical signal output of the controller 1016, namely an output of electrical energy, electrical power, voltage, current or amperage the degree or amount of which can be readily and controllably varied by conventional electrical output devices. The electro-mechanism is controllably drivable to cause the valve 1600 to open or close to a degree of openness that is proportional to the amount or degree of electrical energy that is input to drive the electro-mechanism. The velocity of upstream withdrawal travel of the pins 1041, 1042 are in turn proportional to the degree of openness of the valve 1600.

FIGS. 8A-8D show various examples of position sensors, the mounting and operation of which are described in U.S. Patent Publication No. 2009/0061034, the disclosure of which is incorporated herein by reference. As shown the position sensor 800 of FIGS. 8A and 8B for example can track and signal the position of the piston of an actuator piston 823 continuously along its entire path of travel from which data a pin velocity can be continuously calculated over the length of RP via a spring loaded follower 802 that is in constant engagement with flange 804 during the course of travel of piston 823. Mechanism 800 constantly sends signals to controller 1016 in real time to report the position of pin 1041 and its associated actuator. FIGS. 8C, 8D show alternative embodiments using position switches that detect position at specific individual positions of the actuator and its associated valve pin 1041. The FIG. 8C embodiment uses a single trip position switch 830 a with trip mechanism 833 that physically engages with the piston surface 823 a when the piston 823 reaches the position of the trip mechanism 833. The FIG. 8D embodiment shows the use of two separate position switches 830 a, 830 aa having sequentially spaced trips 833 aa and 833 aaa that report the difference in time or distance between each trip engaging surface 823 a of the piston, the data from which can be used by controller 1016 to calculate velocity of the actuator based on the time of travel of the actuator from tripping one switch 830 a and then tripping the next 830 aa. In each embodiment the position switch can signal the controller 1016 when the valve pin 1041, 1042 has travelled to one or more selected intermediate upstream gate open positions between GC (gate closed) and RP so that the velocity of the pin can be adjusted to the selected or predetermined velocities determined by the user. As can be readily imagined other position sensor mechanisms can be used such as optical sensors, sensors that mechanically or electronically detect the movement of the valve pin or actuator or the movement of another component of the apparatus that corresponds to movement of the actuator or valve pin.

In alternative embodiments the controller can include a processor and instructions that receive the pin position information and signals from the position sensor and calculate the real time velocity of the pin from the pin position data in real time at one or more times or positions over the course of the pin travel through the RP path length and/or beyond. Typically such calculations of velocity are continuous throughout the cycle. In such an embodiment, the calculated pin velocity is constantly compared to a predetermined target profile of pin velocities and the velocity of the pin is adjusted in real time by the controller 1016 to conform to the profile. In this embodiment, as in the previous described embodiment, the pin is moved continuously upstream at all times between the gate closed position and all positions upstream of the gate closed position. Such control systems are described in greater detail in for example U.S. Patent Publication No. 2009/0061034, the disclosure of which is incorporated herein by reference.

As discussed above, control over the velocity of pin movement in an embodiment where the pin is driven by a hydraulic or pneumatic actuator is typically accomplished by controlling the degree of openness of the fluid restriction valve 1600, control over velocity and drive rate or position of valve 1600 being the same functions in terms of the instructions, processor design or computer software that carries out instructing and implementing the velocity or drive rate adjustment to the valve pin or actuator. Where the position sensing system senses the position of the pin or other component multiple times throughout the course of the pin or other component movement, and real time velocity can be calculated by the controller 1016, a program or instructions can be alternatively used to receive a velocity data input by the user to the controller 1016 as the variable to be stored and processed instead of a predetermined voltage or current input Where an actuator that comprises an electric motor is used as the drive mechanism for moving the valve pin 1041, 1042 instead of a fluid driven actuator, the controller 1016 can similarly be programmed to receive and process velocity data input as a variable for controlling the velocity or rate of drive of the electric actuator.

User Interface and Target Profiles

FIG. 9 shows time versus pressure graphs (1235, 1237, 1239, 1241) of the pressure detected by four pressure transducers associated with four nozzles mounted in a manifold block. The four nozzles are substantially similar to the nozzles shown in FIG. 6 and include pressure transducers coupled to the controller 1016.

The graphs of FIGS. 9A-9D are generated on a user interface (e.g., 21, 71 of FIG. 1), so that a user can observe the tracking of the actual pressure versus the target pressure during the injection cycle in real time, or after the cycle is complete. The four different graphs of FIG. 9 show four independent target pressure profiles (“desired”) emulated by the four individual nozzles. Different target profiles are desirable to uniformly fill different sized individual cavities associated with each nozzle, or to uniformly fill different sized sections of a single cavity. Graphs such as these can be generated with respect to any of the previous embodiments described herein.

The valve pin associated with graph 1235 is opened sequentially at 0.5 seconds after the valves associated with the other three graphs (1237, 1239 and 1241) were opened at 0.00 seconds. At approximately 6.25 seconds, at the end of the injection cycle, all four valve pins are back in the closed position. During injection (for example, 0.00 to 1.0 seconds in FIG. 9B) and pack (for example, 1.0 to 6.25 seconds in FIG. 9B) portions of the graphs, each valve pin is controlled to a plurality of positions to alter the pressure sensed by the pressure transducer associated therewith to track the target pressure.

Through the user interface, target profiles can be designed, and changes can be made to any of the target profiles using standard (e.g., windows-based) editing techniques. The profiles are then used by controller 1016 to control the position of the valve pin. For example, FIG. 10 shows an example of a profile creation and editing screen 1300 generated on a user interface.

Screen 1300 is generated by a windows-based application performed on the user interface, e.g., any of the user interfaces 21 shown in FIG. 1. Alternatively, this screen display could be generated on an interface associated with the controller (e.g., display 71 associated with controller 8 in FIG. 1). Interactive screen 1300 provides a user with the ability to create a new target profile or edit an existing target profile for any given nozzle and cavity associated therewith.

A profile 1310 includes (x, y) data pairs, corresponding to time values 1320 and pressure values 1330 which represent the desired pressure sensed by the pressure transducer for the particular nozzle being profiled. The screen shown in FIG. 10 is shown in a “basic” mode in which a limited group of parameters are entered to generate a profile. For example, in the foregoing embodiment, the “basic” mode permits a user to input start time displayed at 1340, maximum fill pressure displayed at 1350 (also known as injection pressure), the start of pack time displayed at 1360, the pack pressure displayed at 1370, and the total cycle time displayed at 1380.

The screen also allows the user to select the particular valve pin they are controlling displayed at 1390, and name the part being molded displayed at 1400. Each of these parameters can be adjusted independently using standard windows-based editing techniques such as using a cursor to actuate up/down arrows 1410, or by simply typing in values on a keyboard. As these parameters are entered and modified, the profile will be displayed on a graph 1420 according to the parameters selected at that time.

By clicking on a pull-down menu arrow 1391, the user can select different nozzle valves in order to create, view or edit a profile for the selected nozzle valve and cavity associated therewith. Also, a part name 1400 can be entered and displayed for each selected nozzle valve.

The newly edited profile can be saved in computer memory individually, or saved as a group of profiles for a group of nozzles that inject into a particular single or multi-cavity mold. The term “recipe” is used to describe one or more of profiles for a particular mold and the name of the particular recipe is displayed at 1430 on the screen icon.

To create a new profile or edit an existing profile, first the user selects a particular nozzle valve of the group of valves for the particular recipe group being profiled. The valve selection is displayed at 1390. The user inputs an alpha/numeric name to be associated with the profile being created, for family tool molds this may be called a part name displayed at 1400. The user then inputs a time displayed at 1340 to specify when injection starts. A delay can be with particular valve pins to sequence the opening of the valve pins and the injection of melt material into different gates of a mold.

The user then inputs the fill (injection) pressure displayed at 1350. In the basic mode, the ramp from zero pressure to max fill pressure is a fixed time, for example, 0.3 seconds. The user next inputs the start pack time to indicate when the pack phase of the injection cycle starts. The ramp from the filling phase to the packing phase is also fixed time in the basic mode, for example, 0.3 seconds.

The final parameter is the cycle time which is displayed at 1380 in which the user specifies when the pack phase (and the injection cycle) ends. The ramp from the pack phase to zero pressure may be instantaneous when a valve pin is used to close the gate, or slower in a thermal gate due to the residual pressure in the cavity which will decay to zero pressure once the part solidifies in the mold cavity.

User input buttons 1415 through 1455 are used to save and load target profiles. Button 1415 permits the user to close the screen. When this button is clicked, the current group of profiles will take effect for the recipe being profiled. Cancel button 1425 is used to ignore current profile changes and revert back to the original profiles and close the screen. Read Trace button 1435 is used to load an existing and saved target profile from memory. The profiles can be stored in memory contained in one or more of the operator interface 21, the main MCU 9, and the recipe storage MCU 16. Save trace button 1440 is used to save the current profile. Read group button 1445 is used to load an existing recipe group. Save group button 1450 is used to save the current group of target profiles for a group of nozzle valve pins. The process tuning button 1455 allows the user to change the settings (for example, the gains) for a particular nozzle valve in a control zone. Also displayed is a pressure range 1465 for the injection molding application.

While specific embodiments of the present invention have been shown and described, it will be apparent that many modifications can be made thereto without departing from the scope of the invention. For example, in one embodiment the controller is mounted on a hydraulic power unit. In one embodiment, the flow control MCU receives, displays and/or records a signal from an electronic mold counting sensor for correlating detected pin motion data to the recipe data for a given molding cycle. In one embodiment, the system includes a plurality of flow control MCU's each controlling a corresponding one of a plurality of pins. In one embodiment, the flow control MCU transmits signals to an electric motor for controlling one or more of pin position and rate of pin movement. In one embodiment, both the recipe MCU and the flow control MCU are mounted to the mold. In one embodiment, the controller is contained in a physical box which is mounted to the injection machine and/or placed near the injection machine. In one embodiment, the controller associates (compares) the recipe data to data collected during one injection cycle. In one embodiment, each valve pin has its own profile per injection cycle, and the recipe is a collection of such profiles for a plurality of pins.

In one embodiment, a mold having no recipe or a non-approved (not current or previously tested) recipe stored in the recipe storage MCU, is mounted to the machine. An operator can then create a recipe by testing different inputs to the controller, e.g., adjusting the rate of speed and/or position of one or more pins. When the user is satisfied with the parts being produced in the mold or with data and/or signals received from the mold (e.g., temperature and/or pressure), the operator then stores a copy of the newly created recipe by transmitting (direct or indirectly) the new recipe for storage on the recipe storage MCU. The main MCU of the controller stores a local copy of the new recipe, and runs the recipe (executes instructions implementing the recipe) for the mold. Then later, if this first mold is removed and a new mold is mounted to the machine, where the new mold has a proper recipe already stored on the new mold MCU, the controller can then immediately run the new recipe for the new mold on the machine. If not, the operator can again create a new recipe for the new mold, as previously described.

The recipe data typically comprises a profile of values of a condition of the injected polymer material or a condition or position of a selected component of the injection molding apparatus that is specified to occur at each point in time over the course or duration of an injection cycle when a part is produced in the mold cavity. Thus a profile defines a set of conditions, events or positions to which the injection material or the component of the apparatus is adjusted to attain over the course of a particular injection cycle. Typical injection material conditions that can be specified and controlled are pressure of the injection material at selected positions within a flow channel of the manifold, within an injection nozzle or within the mold cavity. Typical conditions or positions of components of the apparatus that can be controlled and comprise a profile are the position of the valve pin, the position of the screw of the barrel of the injection molding machine and position of an actuator piston. Such profiles and recipes are disclosed in detail in for example U.S. Pat. Nos. 6,464,909 and 8,016,581 and 7,597,828, the disclosures of which are incorporated by reference as if fully set forth herein.

Various other embodiments will be apparent to the skilled person. Accordingly, the invention is not limited by the foregoing embodiments. 

1. A flow control system for implementing an injection molding process in which one or more nozzles, during an injection cycle, feed fluid material(s) into a cavity of a mold, each nozzle having an associated valve pin, driven by an associated actuator, for opening and closing a respective gate into the cavity, and a position sensor is associated with each valve pin for monitoring a plurality of actual pin positions with respect to the gate and generating a sensor output signal indicative of the plurality of actual pin positions as the valve pin moves between gate closed and gate open positions, the flow control system comprising: a junction box coupled to a recipe storage on the mold and providing a wireless communication interface for transmitting and receiving wireless communications with each of: a controller that controls movement of each valve pin over the course of the injection cycle in accordance with a set of process parameters, the controller being in wireless communication with the junction box; a mobile user interface, in wireless communication with the junction box, configured to receive input from a human operator in the form of process parameters and commands relating to the injection molding process for wireless transmission to at least one of the junction box and the controller; the flow control system being configured to receive and process the sensor output signal from an associated position sensor to determine, from the plurality of actual pin positions, one or more actual process parameters; and a user display being configured to receive and display the plurality of actual pin positions and/or the one or more actual process parameters by which a human operator can track the molding process in real time during the injection cycle.
 2. The system of claim 1, wherein the user display is provided on the mobile user interface.
 3. The system of claim 2, wherein the wireless communication interface comprises a radio frequency (RF) transceiver configured for bi-directional communication with the mobile user interface.
 4. The system of claim 3, wherein the RF transceiver consists of one or more of a Wi-Fi antenna, a Bluetooth antenna, and an NFC (Near Field Communication) antenna.
 5. The system of claim 3, wherein the flow control system is configured to use the RF transceiver to transmit, to the mobile user interface, data indicative of the plurality of actual pin positions and/or the one or more actual process parameters.
 6. The system of claim 3, wherein the flow control system is configured to use the RF transceiver to transmit, to the mobile c user interface, data comprising one or more of: pin position status; pin opening and/or pin closing times; pin opening and/or pin closing velocities; and continuous actual pin position data for a graphical display of the plurality of actual pin positions versus time.
 7. The system of claim 1, wherein: one or more of the junction box and the controller are configured to process the sensor output signal to generate a control signal to control the pin position; and the mobile user interface is configured to receive user input for adjusting the control signal to control the pin position,
 8. The system of claim 1, wherein the mobile user interface includes operator commands for one or more modes of operation including calibration, continuous monitoring of the actual pin position, and discrete determination of the actual pin position as opened or closed.
 9. The system of claim 8, wherein calibration is triggered by an operator input to the mobile user interface from the human operator.
 10. The system of claim 9, wherein in response to the operator input the mobile user interface is configured to generate a calibration command and transmit the calibration command to one or more of the junction box and the controller.
 11. The system of claim 10, wherein one or more of the junction box and the controller are configured to calibrate the position sensor associated with each valve pin in response to the calibration command being received by one or more of the junction box and the controller.
 12. The system of claim 11, wherein calibration data for each calibrated position sensor is stored locally in a memory of the junction box.
 13. The system of claim 2, wherein the mobile user interface comprises a mobile telephone, smartphone, or tablet.
 14. The system of claim 2, wherein the display comprises a display for viewing one or more of: a status indicator of the actual pin position; a graph of the actual pin position versus time; and the actual pin opening time and pin opening velocity.
 15. The system of claim 1, wherein the position sensor comprises a Hall Effect sensor or a Hall Effect circuit including a Hall Effect sensor and one or more of a power regulator, signal amplifier, current converter, and signal driver.
 16. The system of claim 15, wherein: the Hall Effect sensor generates a voltage output signal; the voltage output signal is amplified and converted to a current output signal by the Hall Effect circuit; and the current output signal is transmitted as the sensor output signal from an output port of the Hall Effect circuit to an input port of the junction box or the controller.
 17. A method of monitoring valve pin positioning in an injection molding system having a cavity with one or more gates and one or more actuator-driven valve pins each associated with a respective gate for opening and closing the respective gate, the method comprising, for each of the respective actuator-driven valve pins: controlling, via a flow control system that implements a set of process parameters for controlling a molding process in the cavity, an actuator that drives an associated valve pin with respect an associated gate of the cavity along a travel path including a plurality of actual pin positions between gate open and gate closed positions; detecting, via a position sensor that monitors movement of an associated valve pin while the valve pin moves along the travel path between the gate closed position, closing the associated gate to the cavity, to the gate open position, allowing fluid material to flow through the gate and into the cavity, and transmitting as a position sensor output signal to the flow control system a detected actual movement of the valve pin along the travel path upon opening of the gate indicative of an actual pin opening velocity and an actual pin opening time; receiving the position sensor output signal and generating display data indicative of actual process parameters including the actual pin opening time and the actual pin opening velocity; and displaying, via a user display, the display data enabling a human operator to track the actual process parameters in real time during the injection cycle including the actual pin opening time and the actual pin opening velocity; wherein the flow control system includes a junction box coupled to a recipe storage on the mold and providing a wireless communication interface for transmitting and receiving wireless communications with each of the controller and a mobile user interface, and the method further comprising: receiving, by the mobile user interface, input from a human operator in the form of process parameters or commands relating to the injection molding process for wireless transmission to at least one of the junction box and the controller.
 18. The method of claim 17, wherein the user display is provided on the mobile user interface.
 19. The method of claim 18, wherein the method comprises using a radio frequency (RF) transceiver as the wireless communication interface to perform bi-directional communication with the mobile user interface.
 20. The method of claim 19, wherein the RF transceiver comprises one or more of a Wi-Fi antenna, a Bluetooth antenna, and an NFC (Near Field Communication) antenna.
 21. The method of claim 20, wherein the displaying step includes generating as the display data continuous actual pin position data for a graphical display of the plurality of actual pin positions versus time and transmitting the display data to the mobile user interface via the RF transceiver.
 22. The method of claim 17, wherein the controlling step includes: using the position sensor output signal as a variable input to control subsequent movement of the valve pin in accordance with the actual process parameters; and receiving, at the mobile user interface, user input for adjusting the control signal to control the pin position.
 23. The method of claim 17, wherein the method is adapted for use in calibration of the injection molding system, wherein calibration is triggered by an input to the mobile user interface from the human operator.
 24. The method of claim 23, wherein the mobile user interface is configured to generate a calibration command and transmit the calibration command to one or more of the junction box and the controller via the RF transceiver.
 25. The method of claim 24, wherein one or more of the junction box and the controller calibrate the position sensors associated with each valve pin in response to the calibration command being received by the RF transceiver.
 26. The method of claim 25, further comprising storing calibration data for each calibrated position sensor locally in a memory of the junction box.
 27. The method of claim 17, wherein the displaying step comprises displaying a status indicator of the actual pin position for one or more of the pins of the injection molding system.
 28. The method of claim 17, wherein the displaying step comprises displaying data comprising one or more of: pin position status; pin opening and/or pin closing time; pin opening and/or pin closing velocities; and continuous actual pin position data for a graphical display of the plurality of actual pin positions versus time.
 29. The method of claim 28, wherein the position sensor comprises one or more Hall Effect sensors for an associated valve pin.
 30. A flow control application for monitoring flow control during an injection molding process in which one or more nozzles, during an injection cycle, feed fluid material(s) into a cavity of a mold, each nozzle having an associated valve pin, driven by an associated actuator, for opening and closing a respective gate into the cavity, and a controller controls movement of the valve pins over the course of the injection cycle in accordance with a set of process parameters, the flow control application providing an interactive screen and a user display on a mobile user interface and a wireless communication channel with at least one of a junction box and a controller for monitoring flow control during the injection cycle, wherein the interactive screen enables an operator to input process parameters or commands, via the wireless communication channel, for one or more of the controller and the junction box for performing a method including steps of: monitoring, via a position sensor associated with each valve pin, a plurality of actual pin positions with respect to the gate and generating a sensor output signal indicative of the plurality of actual pin positions as the valve pin moves between gate closed and gate open positions; processing, via the controller, the sensor output signal from the associated position sensor to determine, from the plurality of actual pin positions, one or more actual process parameters; and displaying, on the user display, the plurality of actual pin positions and/or the one or more actual process parameters by which a human operator can track the molding process in real time during the injection cycle.
 31. The flow control application for implementing the method of claim 30, wherein the wireless communication channel comprises a radio frequency (RF) transceiver on the junction box configured for bi-directional communication with the mobile user interface.
 32. The flow control application for implementing the method of claim 31, wherein the RF transceiver comprises one or more of a Wi-Fi antenna, a Bluetooth antenna, and an NFC (Near Field Communication) antenna.
 33. The flow control application for implementing the method of claim 31, wherein the junction box is further configured to use the RF transceiver to transmit, to the mobile user interface, data indicative of the plurality of actual pin positions and the one or more actual process parameters. 